Princeton Case Company
615 Sherwood Parkway
Mountainside, NJ 07092
service@princetoncase.com
(908) 687-1750

What are the Steps of Designing Custom Carrying Cases with Foam?

plastic carrying cases with foam

Designing a custom carrying case with foam is best broken down into steps. The design and manufacturing process is unique, and when taken piece by piece, it becomes more effective and manageable. Below, we want to highlight the process, from start to finish, of designing and getting custom carrying cases with foam.

Step 1) considering how these cases are customized, the first thing to do is decide what will be carried. It would help if you kept in mind that cases are customized based on the products they were designed to carry. Once the case is constructed, you cannot interchange what is carried (unless it's an exact fit for the original thing).

Step 2) Work closely with the case manufacturers to design the layout of products and the necessary size of the case. As mentioned above, cases are particular to the products they were intended to carry.

Step 3) Once the design is finished, blow molding or injection molding is used to create the case's outer shell. When comparing the two manufacturing methods, blow molded cases are often the stronger and more reliable option. 

Step 4) Once the plastic carrying case is cooled, designers must choose a base foam for the case. Foam inserts come in different materials that have varying characteristics. There is no generic, one foam fits all needs. For the base of a case, the three most used foams are Ester Foam, Pro-Cell Foam, and PE Foam.

Step 5) The last part of the manufacturing process is choosing foam for the case's lid. Designers choose between flat/solid foam and convoluted foam. These two types of foam offer excellent protection to devices and products in the case.

Step 6) The last part of the whole process is shipping the case.  Although this is the easiest part of the process for the designer and manufacturer, it is often seen as the most challenging part for the consumer because no one likes waiting for their beautiful new custom carrying case with foam inserts.

Related Reading:

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Princeton Case Company, Inc.

615 Sherwood Parkway
Mountainside, NJ 07092
(908) 687-1750